NHTSA Complaint #10057003 — 2002 CHEVROLET AVALANCHE

OVERTIME I KEPT HEARING A WHINING NOISE, SMELL OF OIL, HEAT AND LIGHT VIBRATION FROM THE DRIVELINE. AT THE DEALERSHIP ON A 100, 000 MILE TOTAL OIL, TRANSMISSION AND COOLANT CHANGE (DID THIS AT 97,018 MI. 1/2/04). THE MECHANIC DID NOTICE A BIT OF PLAY IN THE FRONT & REAR DRIVELINE (DRIVE SHAFTS FROM TRANSFER CASE TO THE FRONT WHEEL AXLE CASE AND THE REAR AXLE CASE), SOME OIL LEAKAGE ON THE RIGHT FRONT AXLE, BOTH SIDES OF THE REAR AXLE, THIS WAS NORMAL HE TOLD ME. MECHANIC FOUND BOTH FINE AND SMALL PIECES OF METAL IN THE FRONT 4X4 TRANSMISSION CASE, BUT SAID THIS WAS NOT A BIG PROBLEM. MECHANIC SUGGESTED THAT I SHOULD HAVE THE U-JOINTS REPLACED SOMETIME ON THE DRIVE SHAFTS AND THIS WOULD STOP THE NOISE AND VIBRATION. AT COLDWATER, MI. (1/14/04), I HAD TO REPLACE A RIGHT FRONT HUB BEARING; MECHANIC REPORTED TO ME THAT HE WOULD LIKE TO INSPECT THE REAR AXLE FOR NOISE. MECHANIC FOUND SOME PLAY IN THE DRIVELINE U-JOINTS, RIGHT REAR AXLE AND PINION SHAFT, AND SOME NOISE COMING FROM THE DIFFERENTIAL. ON 1/26/04 I HAD BOTH REAR & FRONT DRIVESHAFT U-JOINTS REPLACED & BALANCED (FLEET PRIDE SAID THERE WAS SOME PLAY IN THEM). THE NOISE AND VIBRATION STOPPED, BUT THE OIL & HOT SMELL STAYED. THEN THE LIGHT VIBRATION AND SOME NOISE (BETWEEN THE SPEEDS OF 40-75 MPH) STARTED TO RETURN IN JUST 150 MILES. AT 106,606 MILES THE REAR AXLE STARTED TO MAKE A CLUNKING NOISE AND HARD VIBRATION THEN STOPPED TURNING AT 106,607 MILES. I HAD THE REAR AXLE REMOVED AND FOUND THAT THE MAIN BEARING ON THE LEFT SIDE OF THE MECHANICAL LOCKING DIFFERENTIAL (EATON G-80) HAD BROKE APART SENDING METAL THROUGH OUT THE REAR AXLE AND DESTROYED AXLE DRIVE SYSTEM. I HAVE PICTURES OF THE PARTS & DAMAGE TO THE REAR. THE FRONT AXLE IS STARTING THE SAME THING, LEAKING, HOT SMELL AND NOISE. I HAVE FOUND THROUGH YOUR SYSTEM THAT THEY HAVE BEEN HAVING PROBLEMS AND WHEN I ASKED THE DEALERSHIP ABOUT THIS, THEY SAID THEY ARE CHECKING INTO IT. SERVICE BULLETINS 03-04-17-001, 03-07-30-005, 02-04-21-005A. *AK